N465FE

Part: LIGHT — LOOSE (COCKPIT) · airframe 53,611 hrs · 38,255 cycles

EMERGENCY EXIT LIGHT IN COCKPIT POPS OUT OF ITS HOUSING ON ROTATION AND LANDING. FOUND LIGHT NOT PROPERLY SET, RE-SET SAME, OPS CHECK NORMAL AND NOW IS SECURE. ACCOMPLISHED IAW MM 33-50-101-2-0.

Part: LIGHT — DAMAGED (COCKPIT) · airframe 53,611 hrs · 38,255 cycles

COCKPIT EMERGENCY EXIT LIGHT DOES NOT TEST ON PRE-FLIGHT. R & R COCKPIT EMERGENCY LIGHT ASSY IAW AMM 33-50-101-2-0, OPS CHECKS GOOD. R/I FROM FACT PREMATURE REMOVAL/INSTALLATION. R & R COCKPIT EMERGENCY LIGHT ASSY IAW AMM 33-50-101-2-0, OPS CHECKS GOOD. AWAITING TDR RESULTS

Part: RIB — CRACKED (NR 3 SLAT) · airframe 53,154 hrs · 37,870 cycles

NR 3 SLAT HAS 2 CRACKED RIBS, INBD AND OTBD OF ACTUATOR FWD ATTACHMENT. REMOVED CRACKED RIBS, FABRICATED NEW RIBS, HEAT TREATED RIBS TO T4 CONDITION IAW FASI FORM 2-37153-801 REV A AND INSTALLED IAW SRM 51-30-2 AND 51-20-1.

Part: ANGLE — CRACKED (NR 1 SLAT) · airframe 53,154 hrs · 37,870 cycles

NR 1 SLAT LWR AFT CHORD ANGLE IS CRACKED BELOW ACTUATOR. REMOVED ACCESS PANEL IAW SRM 51-30-2, CUT OUT DAMAGED AREA IAW SRM 51-10-1 REV 101, FABRICATED NEW LOWER CHORD, AND 1 EACH SPLICER IAW SRM 57-50-2 FIG 2 AND 51-40-4 FIG 1 REV 101, TREATED AND PRIMED REPAIR PARTS IAW SRM 51-10-2, INSTALLED NEW LOWER CHORD IAW SRM 51-30-2 REV 101, INSTALLED ACCESS PANEL IAW SRM 51-30-2, REV 101.

Part: STRUCTURE — CRACKED (RT WING TE FLAP) · airframe 53,154 hrs · 37,870 cycles

R/WING INBD MIDFLAP T/E CHORD CRACKED AT NR 2 AFT FLAP HINGE CUTOUT. REMOVED LOWER CHORD SECTION IAW SRM 51-30-2 LOCATED AND DRILLED NEW LOWER CHORD, INSTALLED NEW CHORD IAW SRM 51-30-2 REV 101 INSTALLED LOWER MIDFLAP PANEL IAW SRM 51-30-2 REV 101.

Part: SKIN — GOUGED (LT WING TE FLAP) · airframe 53,154 hrs · 37,870 cycles

LT INBD MIDFLAP UPPER SURFACE IS GOUGED WBL 80. MIDFLAP REMOVED AND REPLACED DUE TO DAMAGE BEING OUT OF LIMITS AND BEYOND ECONOMICAL REPAIR.

Part: SHEAR TIE — CORRODED (100) · corrosion level 2 · airframe 53,154 hrs · 37,870 cycles

AFT PIT CORROSION AT SHEAR TIE STA 950E STR 29R REMOVED CORROSION AND FOUND OUT OF LIMITS, CUT OUT SHEAR TIE, FABRICATED REPAIR ANGLE USING 7075-0 .080 PO NR 9008557 DIMS 6" X 2", HEAT TREATED ANGLE TO T6 CONDITION IAW FASI FORM 2-37153-801 REV A AND INSTALLED IAW SRM 51-30-2, 53-10-1, AND 53-10-4.

Part: SKIN — GOUGED (RT WING FOREFLAP) · airframe 53,154 hrs · 37,870 cycles

RT OTBD FOREFLAP, GOUGED AND CHAFED AT OTBD L/E. GOUGE OUT OF LIMITS IAW SRM 51-30-2, FABRICATED REPAIR DOUBLER, IAW SRM 57-50-4, FIG 1 REV 101, TREATED AND PRIMED REPAIR DOUBLER IAW SRM 51-10-2, INSTALLED DOUBLER REPAIR IAW SRM 51-30-2, REV 101.

Part: FRAME — CORRODED (BS 400) · airframe 53,154 hrs · 37,870 cycles

E AND E COMPARTMENT BS 400 STR 19R CORROSION NEXT TO TOOLING HOLES. REMOVED CORROSION AND FOUND OUT OF LIMITS, CUT OUT DAMAGED AREA DIMS 1" DIAMETER, FABRICATED NEW FRAME REPAIR USING 7075-0 .050 PO NR 29016223, DIMS 9 3/4" X 5 1/2", HEAT TREATED PART TO T6 CONDITION IAW FASI FORM 2-37153-801 REV A AND INSTALLED IAW SRM 51-10-6, 53-10-1, 51-40-3, AND 51-30-2.

Part: LAP JOINT — DAMAGED (BS 620 S27L) · airframe 53,154 hrs · 37,870 cycles

STA 620, STR 27L, LAP SEAM LWR ROW, NO DISTANCE BETWEEN RIVETS. REMOVED FASTENERS, CUT OUT DAMAGED AREA, FABRICATED DOUBLERS AND INSTALLED REPAIR AND FASTENERS IAW SRM 51-30-2, 53-30-3, 51-30-8 AND 51-10-2.

Part: FRAME — CRACKED (BS 1263) · airframe 53,154 hrs · 37,870 cycles

AFT AIRSTAIR RT LWR TORQUE BOX, UPPER WEB SUPPORT ANGLE IS CRACKED AT STA 1263 ON AFT SIDE RADIUS. REMOVED WEB DOUBLER, REMOVED CRACKED ANGLE, FABRICATED NEW ANGLE USING 7075-0 .090 PO 9008486 DIMS 18" X 5 7/8", HEAT TREATED ANGLE TO T6 CONDITION IAW FASI FORM 2- 27153-801 REV A, INSTALLED ANGLE AND WEB DOUBLER IAW SRM 51-30-2, 51-30-5 AND DWG PL 65-17517.

Part: FLOOR SUPPORT — CORRODED (BS 300-340) · corrosion level 2 · airframe 53,154 hrs · 37,870 cycles

L-1 ENTRANCE WALK WAY BS 300-340, LBL 56- RBL 30, FLOOR SUPPORTS LWR SURFACES HAVE CORROSION AT N/P HOLES AS MARKED. REMOVED CORROSION AND FOUND OUT OF LIMITS, CUT OUT DAMAGED AREA DIMS 2" X 1", FABRICATED 2 EACH REPAIR ANGLES USING 7075-0 .063 PO 9008655 DIMS 12" X 1" X 1" AND 10 1/8" X 1" X 1" AND 1 REPAIR FILLER USING 2024T-3 .063 PO 9008963, HEAT TREATED REQUIRED PARTS TO T-6 CONDITION IAW FASI FORM 2-37153-801 REV A AND INSTALLED PARTS IAW SRM 53-10-1, 51-10-2 AND DWG SR27-53-017 REV A.

Part: ANGLE — CRACKED (BS 1273) · airframe 53,154 hrs · 37,870 cycles

AFT AIRSTAIR RT LOWER TORQUE BOX, UPPER WEB SUPPORT ANGLE IS CRACKED AT STA 1273 ON FWD SIDE RADIUS. REMOVED ANGLE SUPPORT IAW SRM 51-30-2, LOCATED AND DRILLED NEW ANGLE SUPPORT IAW SRM 51-30-5 REV. 101. INSTALLED NEW UPPER WEB SUPPORT ANGLE IAW SRM 51-30-2 REV. 101.

Part: VERTICAL BEAM — MISINSTALLED (BS 1183) · airframe 53,154 hrs · 37,870 cycles

FUSELAGE STA 1183 LWR CHORD LT INBD 17.8 VERT BEAM FASTENERS SPACING SHORT. REPAIR ACCOMPLISHED ON NON-ROUTINE N00323 UNDER WORK ORDER 00045711 IAW EA 7-5310-126851.

Part: VERTICAL BEAM — DAMAGED (BS 1183 BULKHEAD) · airframe 53,154 hrs · 37,870 cycles

AFT CARGO COMPT, BS 1183 PRESSURE BULKHEAD LBL 17.8 VERTICAL BEAM WEB HAS SEVERAL DOUBLE DRILLED HOLES AT WL 190. REPAIR ACCOMPLISHED ON NON-ROUTINE N00323 UNDER WORK ORDER 00045711 IAW EA 7-5310-126851, REFERENCE SDR 09-3493.

Part: STRINGER — DAMAGED (BS 450 3L) · airframe 53,154 hrs · 37,870 cycles

MAIN CARGO AREA, STA 450, STR 3L NO EDGE DISTANCE BETWEEN RIVET AND HOLE. REMOVED FASTENERS AND CUT OUT DAMAGED AREA, FABRICATED ONE FILLER, ONE PLATE, TWO PLATES, TWO PLATES AND INSTALLED IAW SRM 51-30-2, 53-10-3 AND 51-10-2.

Part: SKIN — CORRODED (BS 1050 S27L) · corrosion level 2 · airframe 53,154 hrs · 37,870 cycles

SKIN BULGE STA 1050, STR 27L. FOUND EXFOLIATED CORROSION OUT OF LIMITS ON SKIN, CUT OUT DAMAGED AREA, CUT OUT DAMAGED STRINGER SECTION, FABRICATED REPAIR DOUBLER AND FILLERS, FABRICATED STRINGER REPAIR AND SPLICES, INSTALLED ALL REPAIR PARTS IAW SRM 51-30-2, 53-30-1, 53-10-3, 53-30-3 AND 51-10-2.

Part: KEELBEAM — CRACKED (BS 870) · airframe 53,154 hrs · 37,870 cycles

LT KEELBEAM CHORD IS CRACKED AT BS 870, LBL 4. CUT OUT DAMAGE AREA DIM 2" IAW FEDEX 727 EA 7-5310-135501, FAB REPAIR DOUBLER MAT USED 15-5 PH .071" PO # 290342001 DIM (85/8" X 4") IAW EA 7-5310-135501. ACCOMPLISHED HARDNESS TEST VERIFICATION OF FABRICATED PARTS WITH A HRC NR 41 CONVERTED TO KSI 188 IAW B727 SRM 51-10-3. CADMIUM PLATE REPAIR DOUBLER IAW MM 20-42-01 & 20-42-05, PRIMED REPAIR PART IAW SRM 51-10-2, INSTALLED REPAIR PART IAW EA 7-5310-135501.

Part: STRINGER — CORRODED (BS 740 S27R) · corrosion level 2 · airframe 53,154 hrs · 37,870 cycles

FWD CARGO COMPARTMENT- CORROSION ON STRINGER 27R AT END SPLICE, BS 740. CUT OUT DAMAGE STRINGER IAW SRM 53-10-3 FIG 1. FABRICATED NEW SECTION STRINGER AND 1EA SPLICE IAW SRM 53-10-2 FIG 9 AND 53-10-3 FIG 1. TREATED AND PRIMED IAW SRM 51-10-2. INSTALLED STRINGER & SPLICE REPAIR IAW SRM 51-30-2 REV. 101.

Part: SKIN — DAMAGED (BS 261 S21L) · airframe 53,154 hrs · 37,870 cycles

DRILL START STA 261 STR 21L. CUT-OUT DAMAGED AREA AND FABRICATED REPAIR FILLER AND DOUBLER IAW B727 SRM 53-30-3 FIGURE 3A. TREATED AND PRIMED PARTS IAW SRM 51-10-2, INSTALLED REPAIR PARTS AT BS 261 STRINGER 21LT IAW SRM 53-30-3 FIGURE 3A.

Part: WEB — CRACKED (BS 1323 S20L) · airframe 53,154 hrs · 37,870 cycles

STA. 1323, STR 20, LEFT AFT AIRSTAIR EQUIPMENT AREA, CRACK ON WEB. TRIMMED AREA IAW SRM 51-10-1 REV 101 FABRICATED REPAIR DOUBLER IAW SRM 51-40-2 FIG 5 REV 101 AND SRM 53-10-2 FIG 6 TREATED AND PRIMED IAW 51-10-2 REV 101 INSTALLED DOUBLER AT STA 1323 STR 20L IAW SRM 51-30-2 REV 101.

Part: ANGLE — CRACKED (NR 7 SLAT) · airframe 53,154 hrs · 37,870 cycles

NR 7 SLAT AFT LWR CHORD ANGLE IS CRACKED 2 PLACES BELOW T-DUCT. REMOVED ACCESS PANEL IAW B 727 SRM 51-30-2. REMOVED LOWER CHORD ANGLE IAW SRM 51-30-2. FABRICATED A NEW LOWER CHORD AND 1 EA SPLICE IAW SRM 57-50-2 FIG 2, AND 51-40-4 FIG 1. TREATED AND PRIMED IAW SRM 51-10-2, INSTALLED NEW CHORD IAW SRM 51-30-2. INSTALLED ACCESS PANEL IAW SRM 51-30-2 REV 101.

Part: STRINGER — DAMAGED (BS 580 S21L) · airframe 53,154 hrs · 37,870 cycles

FORWARD CARGO AREA, STA 580, STR 21L, DRILL START ON STRINGER. CUT OUT DAMAGED AREA DIM 17 5/8" LONG IAW SRM 51-10-3 FIG 1 REV 101, FABRICATED HAT SECTION, AND 2 EACH SPLICERS 2 EACH CHANNELS, 2 EACH ANGLES AND 2 EACH FILLERS IAW SRM 53-10-3 FIG 1 AND 53-10-2 FIG 9 TREATED AND PRIMED REPAIR PARTS IAW SRM 51-10-2 INSTALLED REPAIR PARTS, HAT SECTION AND SPLICERS IAW SRM 51-30-2 REV 101.

Part: SKIN — CRACKED (NR 7 SLAT) · airframe 53,154 hrs · 37,870 cycles

NR 7 SLAT INBD HOOK AFT MOUNTING FASTENER IS LOOSE AND EDGE OF COUNTERSINK HAS CRACK INDICATION. HFEC INSPECTED AREA IAW NDTM 51-00-00 PART 6 FIG 23 VERIFIED CRACK ENDS AT EXISTING FASTENER HOLE. FABRICATED DOUBLER FOR NR 7 SLAT INBD AREA IAW SRM 57-50-3 FIG 10 REV 101 TREATED AND PRIMED REPAIR DOUBLER IAW SRM 51-10-2. INSTALLED COUNTERSINK REPAIR WASHERS IAW SRM 51-30-2 INSTALLED REPAIR DOUBLER IAW B727 SRM 57-50-3 FIG 10 REV 101 AND 51-30-2

Part: VERTICAL BEAM — MISINSTALLED (BS 1183 BULKHEAD) · airframe 53,154 hrs · 37,870 cycles

AFT CARGO COMPT, BS 1183 PRESSURE BULKHEAD LBL 17.8 VERTICAL BEAM INBD FLANGE FASTENERS HAVE IMPROPER SPACING IN 4 AREAS. REPAIRED AFT CARGO COMPARTMENT BS 1183 PRESSURE BULKHEAD IAW EA NR 7-53-10-126851.

Part: ACCESSORY UNIT — FAILED (MLG) · airframe 52,020 hrs · 36,979 cycles

AFTER TAKEOFF, WITH GEAR RETRACTED, WHEN WE WENT FROM FLAPS 5 TO FLAPS 2 GOT THE TAKEOFF WARNING HORN, WOULD ONLY EXTINGUISH BY REDUCING POWER. ALSO GOT THE HORN WHEN WE WENT FROM FLAPS 25 TO FLAPS 30 AT LANDING. R & R MLG ACCESSORY UNIT IAW MM 32-09-121-4 AND TESTED NORMALLY IAW MM 32-09-121-5. PERFORMED MLG MODULE ADJ/TEST MIN CHECKED OK IAW MM 32-09-122-5. ACCOMPLISHED NORMAL T/O WARNING SYS TESTS IAW MM 31-26-000-5. SUBSEQUENT TESTS NORM. VERIFIED WIRING OK TO SENSORS. RESISTANCES THRU THE SENSORS MATCH.

Part: WIRE — DAMAGED (UPLOCK SWITCH) · airframe 51,922 hrs · 36,891 cycles

AFT AIRSTAIR LIGHT ILLUMINATED AT ROTATION. RELEASED FOR SERVICE PER MEL/CDL: 52-06-B CATEGORY: C EXPIRATION: 30SEP07 "MEL 52-06-B: AMBER AFT AIRSTAIR DOOR WARNING LIGHT, INOP. PLEASE WORK IN CONJUNCTION WITH TSI: 52-62 9704. REPAIRED WIRE AT SW S273 (UPLOCK SWITCH) AND REPLACED SW S395 (AIRSTAIR HANDLE DETENT SW). INSP CABLES, LATCHES AND CAMS. ALL CK GOOD PER MM 2-70-001-5.

Part: DISPLAY — BURNED (COCKPIT) · airframe 51,748 hrs · 36,754 cycles

PDIS 465 26-12 0009505 20JUN07 PIT OPEN R LOGPAGES: 01339908 APPROX 1 00 HOURS INTO FLIGHT, ALL CREWMEMBERS SMELLED A BURING SMELL AND SAW LIGHT SMOKE, SOURCE UNKNOW. PREFORMED PHASE ONES RED TAB PROCEDURE. DIVERTED INTO KPIT ENT BY: 001395 RPT BY: 235667 AFTER PULLING A/C TO THE GATE. CKED E&E FOR WATER/SMOKE. E&E CKED GOOD. NO WATER OR SMOKE VERY DRY. REMOVED AND REPLACED PAT CRADLE AND TERMINAL. REF TSI 45-13/9508.

Part: SEAT TRACK — CORRODED (ZONE 100) · corrosion level 2 · airframe 51,714 hrs · 36,706 cycles

CABIN FLOOR SEAT TRACK HAS CORR, FS 460-620, RBL-24". REMOVED CORRODED SEAT TRACK AT RBL 24 , STA 480 TO 620 IAW B727 SRM 53-10-5. FAB NEW SECTION OF SEAT TRACK PO 1142187. TREATED AND PRIMED IAW B727 SRM 51-10-2. INSTALLED SEAT TRACK IAW B727 SRM 53-10-5 FIG#1. REMOVED CABLE GUARD AT STA 480- 500. RECEIVED NEW CABLE GUARD ON TRAVELLER T7/680992 LOCATED AND INSTALLED IAW B727 SRM 51-30-2.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 51,714 hrs · 36,706 cycles

FWD CARGO A/C DISTRIBUTION BAY LT FLOOR STR-26L BADLY CORRODED APPROXIMATELY FS-720F-740. JUST O/B OF DUCT. REMOVED CORRODED SECTION OF STRINGER AT STA 720C TO 740 AND SPLICED IN A NEW SECTION OF STRINGER ON 26L IAW 727 SRM-53-10-3 FIG 1, STRINGER ORIG P/N#65-56236-18.

Part: STRINGER — CORRODED (ZONE 100) · corrosion level 2 · airframe 51,714 hrs · 36,706 cycles

FWD CARGO A/C DISTRIBUTION BAY LT FLOOR STR-26L BADLY CORRODED APPROXIMATELY FS- 720F-740. JUST O/B OF DUCT. REMOVED CORRODED SECTION OF STRINGER AT STA 720C TO 740 AND SPLICED IN A NEW SECTION OF STRINGER ON 26L IAW 727 SRM-53-10-3 FIG 1, STRINGER ORIG P/N NR 65-56236-18.

Part: SEAT TRACK — CORRODED (BS 640) · corrosion level 2 · airframe 51,714 hrs · 36,706 cycles

CABIN FLOOR SEAT TRACK HAS CORROSION FS 640 LBL 1". REMOVED CORROSION IAW 727 SRM 51--10-2 FOUND TO BE OUT OF LIMITS AFTER CORROSION REMOVAL IAW SR 53-10-1. FABBED NEW SEAT TRACK IAW SRM 51-30-2 ,TREATED AND PRIMED IAW SRM 51-10-1. REMOVED AND INSTALLED SEAT TRACK AT BL 0" STA 600 TO 720A IAW SRM 51-30-2.

Part: SKIN — MISREPAIRED (BS 1111-1127) · airframe 51,714 hrs · 36,706 cycles

EXTERNAL REPAIR ON FUSELAGE SKIN STA 1111-1127 AND STR 21R-23R DOES NOT COMPLY PER SRM. REMOVED OLD REPAIR IAW SRM 51-30-2. FABBED NEW DOUBLER IAW SRM 53-30-3 FIG 1 FROM MAT.2024T3 0.05, TREATED AND PRIMED IAW SRM 51-10-2. INSTALLED NEW DOUBLER IAW SRM 53-30-3.

Part: STRINGER — CORRODED (BS 720D-720E) · corrosion level 2 · airframe 51,714 hrs · 36,706 cycles

FWD CARGO COMPT FS 720D-720E STR-26L HAS CORROSION. CUT OUT DAMAGE IAW SRM 53-30-3 FIG 5. FABBED REPAIR DOUBLERS AND FILLER IAW SRM 53-30-3 FIG 5. INSTALLED DOUBLER AND FILLER IAW B727 SRM 53-30-3 FIG 5. THIS REPAIR IS CLASSIFIED AS A MAJOR REPAIR.

Part: SEAT TRACK — CORRODED (BS 848-870) · corrosion level 2 · airframe 51,714 hrs · 36,706 cycles

MAIN CABIN SEAT TRACK CORRODED UPPER SURFACE FROM FSTA 848 - 870, LBL 45 BLENDED SEAT TRACK AT 848 - FS870 LBL 45 FOUND SEAT TRACK TO BE OUT OF LIMITS IAW SRM 53-30-1 (FIG 1); ORDERED NEW SEAT TRACK PART NR BAC1520-841 BATCH NR 3370-1 AND LOCATED AND DRILLED HOLES IAW SRM 51-30-1. TREATED AND PRIMED SEAT TRACK IAW SRM 51-10-2. INSTALLED NEW SEAT TRACK IAW SRM 51-30-2.

Part: WEB — CORRODED (ZONE 100) · corrosion level 2 · airframe 51,714 hrs · 36,706 cycles

AFT CARGO STA 970 S-28R WEB HAS CORROSION. REMOVED CORROSION ON WEB AT STA 970 STR 28R CORROSION FOUND OUT OF LIMITS IAW SRM 51-10-6, FABED NEW WEB ON MAE TR T7/679785. INSTALLED THE NEW WEB IAW SRM 51-30-2. INSTALLED STIFFENERS THAT WERE REMOVED PREVIOUSLY FOR ACCESS IAW SRM 51-30-2.

Part: BRACKET — CRACKED (ZONE 400) · airframe 51,714 hrs · 36,706 cycles

NR 3 PYLON HOLE "P" BRACKET CRACKED FWD OUTBD SEEN INSIDE PYLON AS PER STEP4. 2 ON W/C 7-5410-7-3304. REMOVED AND REPLACED ANGLE( 69-16917-2) IAW SRM 51-30-2 AND 51-10-4. NDT CHECKED "P" HOLE FOR CRACK AND NO CRACK NOTED IAW NTM 51-00-11.

Part: SPAR CAP — CRACKED (ZONE 600) · airframe 51,714 hrs · 36,706 cycles

RT WING UPPER SURFACE AT SPOILER PANEL NR 11 AREA SPAR CAP HAS CRACK AROUND 3RD HINGE FITTING. NDT NOTED NO CRACKED PER NTM 51-00-00 PT6 (AFTER STOP DRILL). STOP DRILLED 0.025" HOLE AT THE END OF CRACKED IAW SRM 57-30-4 FIG10 SHEET 1/3. TREATED AND PRIMED IAW SRM 51-10-2. INSTALLED REPAIR DOUBLER RT WING UPPER SURFACE AT SPOILER PANEL 11 AREA SPAR CAP IAW SRM 57-30-4 FIG 10 SHEET 1 AND 3, CLEANED LOWER AREA OF PANEL NR 11 SPOILER SPAR CAP IAW MM 12-40-000-2, PAGE 1 TO PAGE 14. MINOR REPAIR WING STA 464.

Part: STEERING SYS — MALFUNCTIONED (NLG) · airframe 51,388 hrs · 36,452 cycles

DURING TAKEOFF ROLL, A/C DRIFTED LEFT OF CENTERLINE WITH NO ABILITY TO CONTROL, TAKEOFF ABORTED. SUSPECTED ICY RUNWAY. DURING TAXI IN, NOTICED THAT THE RUDDER PEDALS WOULD NOT STEER A/C TO RIGHT, TILLER WAS REQ'D TO EFFECT RIGHT TURN. RIGHT RUDDER PEDAL DOES NOT APPEAR TO TRAVEL AS FAR THEN PRESSED AS LEFT PEDAL DOES. ACN RELEASED FOR SERVICE.

Part: SWITCH — MALFUNCTIONED (SLAT SYS) · airframe 50,570 hrs · 35,793 cycles

PASSING FL250 RECEIVED INTERMITTENT LE FLAPS AMBER INDICATOR ON FORWARD PANEL WITH INTERMITTENT NR1 SLAT INDICATOR ON S/O AUX PANEL. RAN RED TABS WITH NORMAL EXTENSION TO FLAPS 30. REPLACED NR 1 SLAT RETRACT SWITCH IAW 27-82-011-4, REPLACED NR1 SLAT ACTUATOR PER 27-81-032-4. INDICATIONS NORMAL. RI

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 50,364 hrs · 35,639 cycles

SEAT TRACK STA 480-620 LBL 24 FLANGE HAS CORROSION. REMOVED, FABRICATED, ALODINED, PRIMED AND INSTALLED NEW SEAT TRACK AT STA 480-690 ON LBL 24 ALL IAW FX B727 SRM 53-10-5, 53-10-2, 51-30-2 AND 51-10-2.

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 50,364 hrs · 35,639 cycles

SEAT TRACK AT LBL 45 STA 690-740 IS CORRODED. REMOVED, FABRICATED, ALODINED, PRIMED AND INSTALLED NEW SEAT TRACK FROM STA 680-740 AT LBL45 ALL IAW FX B727-200 SRM 53-10-5,53-10-1 FIG 3, 51-30-2 AND 51-10-2.

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 50,364 hrs · 35,639 cycles

SEAT TRACK STA 600-620 AT LBL 45 IS CORRODED. REMOVED, FABRICATED, ALODINED, PRIMED AND INSTALLED SEAT TRACK REPAIR AT STA 590-690 ON LBL45 ALL IAW FX B727-200 SRM 53-10-5, 51-3-2 AND 51-10-2.

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 50,364 hrs · 35,639 cycles

SEAT TRACK LBL 24 HAS 2 SPLICES AND CORROSION STA 380 - STA 480. REMOVED CORROSION, MATERIAL LOSS FOUND OUT OF LIMITS, ORIGINAL THICKNESS .085 MATERIAL REMOVED .029 RAMAINING .056, REMOVED SEAT TRACK. FABRICATED, DRILLED TO FIT, ALODINED, PRIMED AND INSTALLED NEW SEAT TRACK IAW B727 SRM 51-10-1, FIG 6, SRM 51-10-2 AND DWG 65-23-637.

Part: FLOORBEAM — CORRODED (ZONE 200) · airframe 50,364 hrs · 35,639 cycles

CORROSION ON FLOORBEAM AT STA. 344 FROM BL 12 L TO BL 12 R. REMOVED CORROSION FROM FLOOORBEAM UPPER CAP IAW FED-EX SRM 53-10- 1. REMOVED, FABRICATED AND INSTALLED SPLICES AND FLOORBEAM IAW SRDM SR27-53-007, B727 SRM 51-10-2,51-30-2.

Part: FLOORBEAM — CORRODED (ZONE 100) · airframe 50,364 hrs · 35,639 cycles

CORRODED FLOORBEAM FS 620 FROM LBL 24 - LBL 45 THREE HEAVY AREAS. REMOVED, FABRICATED, ALODINED, PRIMED, HEAT TREATED, CAD PLATED AND INSTALLED FLOORBEAM REPAIR AT STA 620 FROM LBL24-45 ALL IAW FX DWG SR27-53-034E REPAIR NR 4 B727SRM 51-10-2,BAC5619H AND AMSPP-8-416.

Part: SEAT TRACK — CORRODED (ZONE 200) · airframe 50,364 hrs · 35,639 cycles

SEAT TRACK INBOARD FLANGE HAS CORROSION BS 700 TO BS 740 LBL 24.

Part: TRANSMITTER — MALFUNCTIONED (EPR) · airframe 50,180 hrs · 35,489 cycles

ON TAKEOFF WITH STANDARD EPR SET NR3 N1,N2 AND FUEL FLOW WERE LOW. AC RELEASED FOR SERVICE IAW MEL/CDL: 77-01-01 01JUL05 14:55 ORF REMOVED PT2 SENSOR FROM ENG, BLEW AIR THROUGH LINE TO INSURE NO OBSTRUCTIONS PRESENT. RE-INSTALLED SAME. DISCONNECTED NR3 ENG EPR PT2 LINE AT PRESSURE TRANSMITTER AND DID SAME. REMOVED AND REPLACED TRANSMITTER AND EPR IND FOR NR 3 ENG. RAN NR 1 AND NR 3 ENGS AT TAKEOFF EPR IAW JRH, ENGS OP CHECK GOOD IAW JRH CHAP 4,PG 4-8. ENT BY: 127651

Part: WARNING LIGHT — ILLUMINATED (NLG) · airframe 49,795 hrs · 35,195 cycles

DURING MANUAL EXTENSION WHEN NOSE GEAR WAS UNLOCKED, BOTH MAINS SHOWED UNSAFE. JACKED ACFT, PERFORMED NOSE GEAR MANUAL EXTENSION, SYSTEM TEST SEVERAL TIMES WITH FLAPS AT DIFFERENT SETTINGS AND PRESSURE ON AND OFF. SYSTEM FUNCTIONAL CHECKS GOOD IAW FED EX M/M 32-34-000-5. DOWN JACKED ACFT IAW FED EX M/M 07-11-000-2.

Part: SKIN — DAMAGED (L1 DOOR) · airframe 49,795 hrs · 35,195 cycles

LBL 70 FWD ENTRY DOOR EXTERNAL SKIN DAMAGED 15.750 INCH FROM LEADING EDGE 15 INCH FROM LOWER EDGE. REMOVED OUT OF LIMITS EXTERNAL SKIN, FABRICATED REPAIR DOUBLER AND FILLER IAW SRM 53-10-1, 51-30-2, AND 52-00-3.

Part: FITTING — CRACKED (FUSELAGE) · airframe 49,795 hrs · 35,195 cycles

WHILE WORKING EO 7-5340-7-4315F PT 2 FOUND 3 EACH HOLES WITH CRACK INDICATION IN LT HAND 940 STR 18A FITTING. REPAIRED BS 940 STR 18A FITTINGS IAW FEDEX EA 7-5340-72401.

Part: SKIN — CRACKED (FUSELAGE) · airframe 49,795 hrs · 35,195 cycles

FUSELAGE SKIN CRACKED AT FWD ENTRY DOOR UPPER HINGE CUTOUT. REPAIRED PER EO 7-5330-7-2345 PT 3.

Part: SKIN — CRACKED (PAX DOOR) · airframe 49,795 hrs · 35,195 cycles

CRACK AT FWD ENTRY DOOR CUTOUT UPPER HINGE, REPAIR PER EO 7-5330-7-2345 PT 2. REPAIRED FWD ENTRY DOOR CUT OUT UPPER HINGE CRACK PER EO 7-5330-7-2345 PART 2

Part: STOP FITTING — DAMAGED (PAX DOOR) · airframe 49,795 hrs · 35,195 cycles

INTERNAL ANGLE AT NR 7 LEFT DOOR STOP HAS MECHANICAL DAMAGE (DRILLED INTO). REMOVED AND REPLACED NR 7 LEFT DOOR STOP FITTING AS PER SRM 51-30-5, 51-30-2.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 49,795 hrs · 35,195 cycles

BS 410 DRILL START NOTED IN SKIN AT L-BAND ANTENNA NR 1 AT BS 410: AT FWD END LT MOUNT HOLE. DAMAGE ON SKIN AT FWD LT BAND ANTENNA MOUNT HOLE FOUND TO BE OUL.. CUT OUT DAMAGE , FABRICATED PART, ALODINED, PRIMED AND INSTALLED IAW SRM 53-10-1, 53-30-3

Part: STOP FITTING — CRACKED (FUSELAGE) · airframe 49,795 hrs · 35,195 cycles

BS 950 LBL 40 WL 149 LT WHEEL WELL AFT BODY DOOR STOP FITTING ASSY HAS CRACKED ANGLE.

Part: SPAR — DAMAGED (HORIZONTAL STAB) · airframe 49,795 hrs · 35,195 cycles

RT HAND HORIZ STAB REAR SPAR LWR CHORD HAS DAMAGE FASTENER HOLE AT NR 4 BAL BAY. *S/D* TRIMMED DAMAGED AREA OUT, FABRICATED REPAIR PARTS AND INSTALLED PER SRM 55-10-5.

Part: FRAME — CRACKED (FUSELAGE) · airframe 49,795 hrs · 35,195 cycles

CRACKED FRAME BS 320 LBL 45 WL 148.5. *S/D* REPAIRED CRACKED FRAME AT BS 320, LBL 45, WL 148.5 IAW SRM 51-40-3 FIG 1 AND SRM 51-40-2 FIG 1.

Part: SKIN — CORRODED (NR 2 NACELLE) · airframe 49,795 hrs · 35,195 cycles

NR 2 ENGINE INLET INNER SKIN DAMAGED 16.5 IN FWD OF ACCESS DOOR LBL 2. REPAIRED PER SRM 54-10-3 FIG. 7

Part: SKIN — MISDRILLED (FUSELAGE)

DRILL START NOTED AT L-BAND NR 1 ANTENNA FWD RT MOUNT HOLE. BS410, RBL 1. (IN SKIN) FOUND WHILE PERFORMING INSPECTION OF ANTENNA IAW WORKCARD NR 34X4505. (K)

Part: FLAP — FAILED (WING) · airframe 47,791 hrs · 33,633 cycles

OUTBOARD FLAPS DID NOT EXTEND PAST 23 ALTERNATE FLAP MOTOR USED TO EXTEND FLAPS.

Part: SKIN — CHAFED (FUSELAGE) · airframe 47,787 hrs · 33,626 cycles

EXTERNAL SKIN CHAFED AT STR 19 LT, BS 720D+13.

Part: SKIN — CHAFED (FUSELAGE)

EXTERNAL SKIN CHAFED AT STR 19R BS 720D+13. REMOVED AND REPLACED SKIN PER SRM 53-30-3 FIG 14.

Part: FRAME — CORRODED (FUSELAGE)

CORROSION ON FRAME AT BS 680 STR 25R. REMOVED AND REPLACED FRAME PER EA 7-5310-65004 & SRM 53-10-9 FIG 11.

Part: FLOORBEAM — CORRODED (FUSELAGE)

CORROSION ON FLOORBEAM AROUND 2 FASTENER HOLES BS 480 RBL 10 WL 208. REMOVED AND REPLACED FLOORBEAM PER SRM 53-10-8 FIG 8.

Part: STRINGER CLIP — CRACKED (FUSELAGE)

INTERIOR CABIN HAS CRACKED STR CLIP AT BS 680 STR 4L. REMOVED AND REPLACED CLIP PER SRM 51-30-2.

Part: FLOORBEAM — CORRODED (FUSELAGE)

CORROSION ON FLOORBEAM AT NUT CLIP LOCATION BS 950F LBL 10.5 WL 208. REMOVED AND REPLACED FLOORBEAM AT BS 950F, LBL 10.5, WL 208 PER SRM 53-10-8 FIG 8.

Part: OXYGEN BOTTLE — FAULTY (OXYGEN SYS) · airframe 47,771 hrs · 33,615 cycles

THIRTY MINUTES INTO FLIGHT AT FL 350 OXYGEN QTY INDICATES ZERO. ALL OXYGEN REGULATORS WERE IN EMERGENCY-OFF POSITION. PERFORMED LEAK CHECK OF OXYGEN LINES IN E&E BAY, NO LEAKS. CHECKED ALL MASKS AT REGULATORS IN COCKPIT, CHECK OK. REPLACED BOTH OXYGEN BOTTLES, O2 PRESSURE 1900 PSI. PERFORMED LEAK CHECK. NO LOSS OF PRESSURE. OK TO CONTINUE.

Part: DUCT — SEPARATED (FUSELAGE)

ON DEPARTURE, THE LWR AFT BODY OVERHEAT LIGHT ILLUM. WHEN WING ANTI-ICE WAS TURNED OFF THE LIGHT WENT OUT. FOUND SURFACE THERMAL ANTI-ICE CROSSOVER DUCT SEPARATED IN LT OVERHEAD STAIRWELL AREA. REASSEMBLED DUCT WORK, CK SATISFACTORY.

Part: SWITCH — FAILED (NR 1 ENG OIL)

98-243 AT CRUISE, FL 330, NR 1 OIL FILTER BYPASS LIGHT CAME ON WHEN THROTTLE WAS RETARD TO IDLE, LIGHT WENT OUT FOR APPROX 2 MIN, THEN CAME BACK ON AND REMAINED ON. ENG WAS SHUT DOWN IN ACCORD WITH RED TAB. OIL TEMP AND PRESS & QUAN NORM. REMOVED AND REPLACED LOW OIL PRESS SWITCH AND RAN. OPER AND LEAK CK ON NR 1 ENG PER MM 79-33-0, AND JET RUN HANDBOOK. OPER CK GOOD. LEAK CK GOOD.

Part: CHORD — CORRODED (BS 309.24)

H-CHORD CORRODED AT END LBL 11, BS 309.24, WL 178. *S/D* REMOVED AND REPLACED H-CHORD AT LBL 11, BS 309.24, WL 178.

Part: DOUBLER — CORRODED (BS 227)

CORROSION FWD SIDE OF BS 227 IN FWD LOWER COMPARTMENT 1 LBL TO 4 RBL UNDER LEVELING COMPOUND AND AFT OF FLAPPER DRAIN SEAL. REMOVED CORROSION AND INSTALLED ANGLE DOUBLER PER SRM 51-40-3.

Part: FLOORBEAM — DAMAGED (BS 344)

BS 344, LBL 58 FWD UPPER FLANGE FLOORBEAM HAS .75 RADIUS CUT IN IT SHARP AND JAGGED. INSTALLED NEW FLOORBEAM CAP SPLICE BS 344, LBL 50 TO LBL 69 PER FED-EX DRAWING SR 27-53-007.

Part: BULKHEAD WEB — CORRODED (BS 1342)

BS 1342 BULKHEAD CENTER WEB RT SIDE UPPER HAS ELONGATED AND WORN BOLT HOLES AND CORROSION IN BOLT HOLE AREAS. REMOVED AND REPLACED WEB SEGMENT PER SRM 51-10-1.

Part: BULKHEAD WEB — CORRODED (BS 1342)

BS 1342 BULKHEAD CENTER WEB LT SIDE UPPER HAS ELONGATED AND WORN BOLT HOLES AND BOLT HOLE AREAS CORRODED. REPLACED LEFT UPPER SECTION PER SRM 51-10-1.

Part: SPLICE — CORRODED (BS 680)

FWD CARGO, STRINGER SPLICE FWD AND AFT OF 680 FRAME CORRODED STR 26L. REMOVED CORRODED STR SPLICE AND INSTALLED NEW SPLICE PER SRM 53-10-3 FIGURE 1.

Part: FRAME — DAMAGED (BS 1070)

AFT CARGO DENTS IN FRAME BS 1070 BETWEEN STR 27R AND 25R. REMOVED DAMAGED AREA, INSTALLED DOUBLER PER SRM 51-40-3.

Part: FRAME — DENTED (BS 950)

AFT CARGO DENT IN FRAME BS 950F, STR 26L. REMOVED DAMAGED AREA AND REPAIRED FRAME PER SRM 51-40-03.

Part: FRAME — DAMAGED (BS 520)

FWD CARGO FRAME BS 520 DENTED AT LWR FWD FLANGE ABOVE STR 23L. REMOVED DAMAGED AREA AND REPAIRED FRAME PER SRM 51-40-03.

Part: FRAME — DENTED (BS 580)

FWD CARGO, FRAME 580 DENTED BETWEEN STRINGERS 22 AND 23 LT. DAMAGED REMOVED PER SRM 51-40-3, DOUBLER INSTALLED PER SRM 51-40-3.

Part: CONNECTOR — DIRTY (GEAR LIGHTS)

AFTER TAKEOFF RED DOORS LIGHT REMAINED ON WITH R GEAR DOOR ON 2ND OFFICERS PANEL. RECYCLED GEAR AND LIGHT REMAINED ON. GEAR HANDLE WAS PUT UP AND BOTH LIGHTS EXTINGUISHED. CYCLED RIGHT GEAR DOOR AND OPS CHECKED OK. CLEANED CANNON PLUG AND OPS CHECKED SEVERAL TIMES, AGAIN WITH DOOR LIGHTS OUT WHEN DOOR CLOSED.

Part: BOLT — LOOSE (RT STAB TRIM)

DURING FLIGHT CONTROL CHECK, ELEVATOR WOULD ONLY MOVE HALFWAY FORWARD. HYDRAULIC PRESSURE WAS GOOD. FOUND RIGHT HAND STAB TRIM CONTROL ROD END ATTACH BOLT MIGRATED OUT, JAMMING POWER PACK. RESECURED BOLT. OPS CHECKS OKAY.

Part: FIRE WARNING — ACTIVATED (GLARE SHIELD)

ON CLIMBOUT, THE FIRE WARNING BELL AND FORWARD FIRE WARNING LIGHTS ON THE GLARE SHIELD MOMENTARILY ILLUMINATED, THEN IMMEDIATELY EXTINGUISHED. NO OTHER LIGHT WAS OBSERVED. TESTED THE FIRE WARNING AND SMOKE DETECTION SYSTEMS AND THEY CHECKED NORMAL. NO FURTHER INDICATIONS WERE OBSERVED. PERFORMED ENGINE FIREWALL AND WHEEL WELL FIRE TEST PER JET RUN HANDBOOK CHAPTER 5. PERFORMED MAIN CARGO SMOKE TEST, ALL TEST NORMAL.

Part: RETRACT MECH — MALFUNCTIONED (LANDING GEAR)

ON CLIMBOUT WHEN RETURNING GEAR LEVER TO OFF POSITION, RED GEAR LIGHTS CAME ON AND GEAR BEGAN TO EXTEND. THE GEAR LEVER WAS QUICKLY RETURNED TO THE UP POSITION RESULTING IN A PARTIAL RETRACTION AT 240 KIAS. COULD NOT DUPLICATE. JACKED AIRCRAFT AND CYCLED GEAR SEVERAL TIMES, NO DEFECTS NOTED. INSPECTED LANDING GEAR DOORS AND WHEEL WELLS, NO DEFECTS NOTED. OK FOR SERVICE.